Molding with integral fixation member

ABSTRACT

A method for manufacturing an insert molding having a conductor member in which a part thereof is coated with resin is disclosed. The method comprises the steps of securely supporting a part of the conductor member by a fixation member provided in a holding member, grasping the holding member supporting the conductor member by a mold so as to accommodate a portion of the conductor member where is other than a portion to be utilized as a contact point, injecting the resin into inside of the mold, and coating the conductor member accommodated in the mold integrally with the holding member by the resin.

BACKGROUND OF THE INVENTION

[0001] 1. Technical Field of the Invention

[0002] The present invention relates to a method for manufacturing aninsert molding, and particularly relates to a method for manufacturingan insert molding in which that portion of a conductor member other thana contact point can be coated with a thin film surely.

[0003] 2. Description of the Related Art

[0004] In a terminal 30 for connecting an electric equipment of a car, apair of bus bars 31 are insert-molded with resin having an insulatingcharacteristic as shown in FIGS. 3(A) to 3(C).

[0005] The bus bars 31 are made into suitable metal plate members havingelectrical conductivity, and disposed in parallel with each other alongthe axial direction of identical columnar circumferential surface in thestate where the respective end portions of the bus bars 31 have beentrued up. These bus bars 31 are projecting outside from a coating 32 inorder to make their respective one end portions act as contact points.

[0006] In manufacturing such a terminal 30, in connection with coating,it is necessary to keep the relative positions of the bus bars 31, orthe relative positions of the bus bars 31 and a mold accurately becausethe bus bars 31 are coated with a thin film.

[0007] Conventionally, thus the terminal 30 was manufactured in a mannersuch that the longitudinal center portions of the bus bars 31 weregrasped between upper and lower mold parts of a mold into which resin isto be injected, and then resin is injected into the mold.

[0008] In the above-mentioned method for manufacturing the terminal 30,however, exposed portions 33 which were not coated with the coating 32were formed because the longitudinal center portions of the bus bars 31were fixed by the upper and lower mold parts.

[0009] Therefore, in the thus manufactured terminal 30, there was a fearthat the terminal 30 or other parts were damaged or short-circuitedbecause of the exposed portions 33 of the bus bars 31.

SUMMARY OF THE INVENTION

[0010] The present invention has been achieved in view of the foregoingproblem, and it is an object thereof to provide a method formanufacturing an insert molding in which in a conductor member, thatportion of a conductor member other than a contact point can be coatedwith a thin film surely.

[0011] In order to achieve the above object, there is provided a methodfor manufacturing an insert molding having a conductor member in which apart thereof is coated with resin comprising the steps of: securelysupporting a part of the conductor member by a fixation member providedin a holding member; grasping the holding member supporting theconductor member by a mold so as to accommodate a portion of theconductor member where is other than a portion to be utilized as acontact point; injecting the resin into inside of the mold; and coatingthe conductor member accommodated in the mold integrally with theholding member by the resin.

[0012] In the method for manufacturing the thus configured insertmolding, the conductor member is held by a holding member grasped in themold. Accordingly, it is possible to held the relative positions of theconductor member and the mold when molten resin is injected into themold. This holding member is integrated with a thin film as the moltenresin injected into the mold is solidified, and there is no fear thatthe holding member projects out from the surface of the thin film.

[0013] That is, in this method for manufacturing insert molding, theholding member for holding the conductor member is integrated with thethin film, so that partially exposed portions conventionally formed inthe conductor member can be eliminated.

[0014] Preferably, the holding member may be made from the same materialas the resin, so that the appearance of insert molding is improved.

[0015] In the holding member, the fixation portion may be formedsubstantially into a C-shape so as to be capable of grasping theconductor member.

[0016] Here, as for the fixation portion, for example, in order to graspa band-like conductor member, any shape will do so long as the gap sizeof the fixation portion set to be a little smaller than the thicknesssize of the conductor member so that the conductor member can be graspedby the elastic deformation of the holding member.

[0017] In the method, a convex portion may be formed in one of theconductor member and the holding member and engaged with the othermember at the time of supporting.

[0018] Here, as for the convex portion, in the case where the conductormember is, for example, like a band, a protrusion may be formed bypressing the plate of the conductor member, a protrusion may be formedintegrally with an end surface when the conductor member is formed bypunching, or the like. Then, the protrusion may be engaged with an edgeportion of the fixation portion for fixing the conductor member, may bepressed onto the inner surface of the fixation portion, or may beengaged with a concave portion provided in the inner surface of thefixation portion. On the other hand, as for the convex portion providedin the holding member, for example, a protrusion may be formed in theinner surface of the fixation portion for fixing the conductor member.Then, the protrusion may be engaged with a recess portion, a notch, ahole, or the like, formed in the conductor member.

[0019] In such a method for manufacturing insert molding, a convexportion provided in one of the conductor member and the holding memberis engaged with the other. Accordingly, the relative positions of theconductor member and the holding member are kept surely.

[0020] On the other hand, the fixation portion may be formed as aninsertion hole to which the conductor member is inserted. According tothis configuration, the conductor member can be fixed surely regardlessof the injection speed of molten resin injected into the mold.

[0021] In addition, the holding member may be formed so as to be broughtinto face contact with an inner wall face of the mold. According to thisconfiguration, the holding member can be grasped firmly regardless ofthe injection speed of molten resin injected into the mold.

[0022] The holding member may be formed so as to be brought into line orpoint contact with an inner wall face of the mold. According to thisconfiguration, it is possible to reduce the area where the holdingmember is exposed from the surface of the coating, so that it ispossible to improve the appearance of insert moldings.

[0023] As for the conductor members, a pair of metal band portionsadopted in the above-mentioned terminal may be shown by way of example.However, according to the present invention, rod or rectangularconductor members are also supposed, and the conductor members are notrequired to be identical in shape to each other are not required to bedisposed in parallel with each other. In addition, the present inventioncan be applied not only to the case where two conductor members or moreare coated with a thin film, but also to the case where a singleconductor member is coated with a thin film.

BRIEF DESCRIPTION OF THE DRAWINGS

[0024] In the accompanying drawings:

[0025]FIG. 1(A) is a partial perspective view showing an embodimentaccording to the present invention, FIG. 1(B) is a partial sectionalview of the same and FIG. 1(C) is a whole plan view of the same;

[0026] FIGS. 2(A) to 2(F) are model diagrams showing another embodimentsof the present invention; and

[0027]FIG. 3(A) is a sectional view showing a conventional insertmolding, FIG. 3(B) is a plan view of the same, and FIG. 3(C) is a rearview of the same.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0028] One preferred embodiment of the present invention will bedescribed below in detail with reference to the drawings. FIG. 1(A) is apartial perspective view of a terminal 10 which is an insert moldingaccording to the present invention, FIG. 1(B) is a partial sectionalview of the same, and FIG. 1(C) is a whole plan view of the same.

[0029] As shown in FIG. 1(C), in the terminal 10, a pair of bus bars 11are insert-molded with resin having an insulating characteristic forconnecting an electric equipment of a car. The bus bars 11 are made intosuitable metal plate members having electrical conductivity, anddisposed in parallel with each other along the axial direction ofidentical columnar circumferential surface in the state where therespective end portions of the bus bars 11 have been trued up. These busbars 11 are projecting outside from a coating 12 in order to make therespective one end portions act as contact points respectively.

[0030] To manufacture such a terminal 10, the bus bars 11 are held by aholding member 14 (see FIG. 1(A)), and then molten resin is injected inthe state where the holding member 14 is grasped between mold parts 15Aand 15B (see FIG. 1(B)).

[0031] The holding member 14 is formed from resin which is the same inmaterial and color as the molten resin, so as to have a substantiallyH-shaped section having a pair of fixation portions 16 and 17. Thefixation portions 16 and 17 are formed into a substantially C-shape. Thegap size of the C-portion is set so as to be a little smaller than thethickness of the bus bars 11, so that when the bus bars 11 are pressedinto the gap, the C-portion is elastically deformed to thereby grasp thebus bars 11 therein.

[0032] The thus configured holding member 14 is formed into a curvedshape so that the holding member 14 can be brought into face contactwith the arcuate inner wall surface of the mold part 15A and the arcuateinner wall surface of the mold part 15B. Accordingly, the holding member14 is firmly grasped between the mold parts 15A and 15B.

[0033] In the thus configured terminal 10, the bus bars 11 are firmlygrasped by the fixation portions 16 and 17 of the holding member 14 atthe time of insert molding. Therefore, the relative positions of the busbars 11 and the holding member 14 are held surely, and this holdingmember 14 is grasped between the mold parts 15A and 15B. Accordingly,the relative positions of the bus bars 11 and the mold parts 15A and 15Bare held surely.

[0034] Therefore, if molten resin is injected into the mold parts 15Aand 15B in this state, it is possible to obtain the terminal 10 in whichthe bus bars 11 are coated with a thin film of the resin up to a desiredthickness properly, and in which partially exposed portion cannot beformed.

[0035] As shown in FIG. 1(C), the holding member 14 is integrated with acoating 12 as the molten resin is solidified, and there is no fear thatthe holding member 14 projects out from the surface of the thin film 12.

[0036] The present invention is not limited to the above-mentionedembodiment, and it can be modified, reformed, etc., suitably.

[0037] For example, although the substantially H-shaped holding memberwhich can be in face contact with the inner wall surface of the mold wasshown by the way of example in the above-mentioned embodiment, theholding member according to the present invention includes such a formas shown in FIGS. 2(A) to 2(F).

[0038] That is, in a holding member 14C shown in FIG. 2(C), fixationportions 16A and 17A are formed as through holes into which bus barswhich are conductor members can be inserted. If this holding member 14Cis adopted, it is further possible to obtain an effect that the bus barscan be fixed surely regardless of the injection speed of molten resininjected into the mold.

[0039] On the other hand, a peak portion 20 which can be in line contactwith the inner wall surface (not-shown) of a mold is formed in a holdingmember 14A shown in FIG. 2(A), while a summit portion 21 which can be inpoint contact with the inner wall surface (not-shown) of a mold isformed in a holding member 14B shown in FIG. 2(B). If either of theseholding members 14A and 14B is adopted, it is possible to obtain aneffect that the area exposed in the surface of the coating can bereduced, so that the appearance of the insert molding can be improved.The fixation portions 16A and 17A are may be formed substantially into aC-shape like the embodiment shown in FIG. 1(A).

[0040] Further, a holding member 14D shown in FIG. 2(D) is formedsubstantially in an S-shape in which apertures of fixation portions 16Band 17B are directed oppositely to each other, and nail portions 18 areprovided at the outer edge portions of the apertures of the fixationportions 16B and 17B, respectively.

[0041] On the other hand, according to the present invention, relativepositioning may be performed by making a convex portion provided in oneof the conductor member and the holding member engage with the other.

[0042] Specifically, bus bars 11A and the holding member 14 shown inFIG. 2(E) are relatively positioned by making convex portions 22integrally formed on the end surfaces of the bus bars 11A engage withopening edge portions of the fixation portions 16 and 17.

[0043] Further, bus bars 11B and a holding member 14E shown in FIG. 2(F)are relatively positioned by making convex portions 23 integrally formedon the inner surfaces of fixation portions 16C and 17C engage withnotches 24 formed in the end surfaces of the bus bars 11B.

[0044] Moreover, materials, shapes, sizes, forms, numbers, locations,etc. of the mold, the conductor member, the resin, the insert molding,the holding member, the fixation portions, the convex portions, and soon, shown in the above embodiment by way of example are not limited andmay be modified so long as the present invention can be attained even bythe modification.

[0045] As has been described heretofore, according to the presentinvention, the conductor member is held by the holding member grasped bythe mold. Accordingly, the holding member is integrated with the thinfilm, so that it is possible to eliminate any partially exposed portionsformed in the conductor member.

[0046] Further, according to the present invention, it is possible toimprove the appearance of the insert molding if the holding member ismade from the same material as resin.

[0047] In addition, according to the present invention, the fixationportions of the holding member is formed substantially in a C-shapewhich can grasp the conductor member. Accordingly, it is possible toperform relative fixation between the conductor member and the holdingmember easily.

[0048] In addition, according to the present invention, it can beconfigured that the fixation portion is formed as the insertion holes towhich the conductor members are inserted. Accordingly, the conductormembers can be fixed surely regardless of the injection speed of moltenresin injected into the mold.

[0049] Further, according to the present invention, it can be configuredthat the holding member is in line contact with the inner wall surfaceof the mold, or that the holding member is in point contact with theinner wall surface of the mold. Accordingly, it is possible to reducethe area of exposure of the holding member in the surface of coating, sothat it is possible to improve the appearance of the insert molding.

[0050] In addition, according to the present invention, it can beconfigured that the convex portion provided in one of the conductormember and the holding member engaged with the other. Accordingly, it ispossible to keep the relative positions of the conductor members and theholding member surely.

What is claimed is:
 1. A method for manufacturing an insert moldinghaving a conductor member in which a part thereof is coated with resincomprising the steps of: securely supporting a part of the conductormember by a fixation member provided in a holding member; grasping theholding member supporting the conductor member by a mold so as toaccommodate a portion of the conductor member where is other than aportion to be utilized as a contact point; injecting the resin intoinside of the mold; and coating the conductor member accommodated in themold integrally with the holding member by the resin.
 2. The method formanufacturing an insert molding as set forth in claim 1, wherein theholding member is made of a material identical with the resin.
 3. Themethod for manufacturing an insert molding as set forth in claim 1,wherein the fixation portion is formed substantially into a C-shape soas to be capable of grasping the conductor member.
 4. The method formanufacturing an insert molding as set forth in claim 3, wherein theholding member is formed so as to be brought into face contact with aninner wall face of the mold.
 5. The method for manufacturing an insertmolding as set forth in claim 3, wherein the holding member is formed soas to be brought into line contact with an inner wall face of the mold.6. The method for manufacturing an insert molding as set forth in claim3, wherein the holding member is formed so as to be brought into pointcontact with an inner wall face of the mold.
 7. The method formanufacturing an insert molding as set forth in claim 3, wherein aconvex portion is formed in one of the conductor member and the holdingmember and engaged with the other member at the time of supporting. 8.The method for manufacturing an insert molding as set forth in claim 1,wherein the fixation portion is formed as an insertion hole to which theconductor member is inserted.
 9. The method for manufacturing an insertmolding as set forth in claim 8, wherein the holding member is formed soas to be brought into face contact with an inner wall face of the mold.10. The method for manufacturing an insert molding as set forth in claim8, wherein the holding member is formed so as to be brought into linecontact with an inner wall face of the mold.
 11. The method formanufacturing an insert molding as set forth in claim 8, wherein theholding member is formed so as to be brought into point contact with aninner wall face of the mold.
 12. An insert molding comprising: aconductor member in which end portion thereof is utilized as a contactpoint; a fixation member for securely holding a portion of the conductormember; and a resin portion for covering the conductor member where isother than the contact point with the fixation menber integrally.